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May 15, 2023 02:02
chamfer millsMachining tools play a crucial role in the manufacturing industry. These tools shape and cut materials into desired shapes and sizes. Choosing the right material for machining tools is a critical decision because it affects the efficiency, durability, and precision of the tool.
Carbide is one of the most popular materials used for making machining tools due to its unique properties. Let’s explore why carbide is the chosen material for machining tools.
What is Carbide?
Carbide is a compound made up of carbon and a metallic element, such as tungsten, titanium, or tantalum. It is a hard and brittle material that is ideal for machining tools because of its wear resistance and high melting point.
Carbide is commonly used in the form of cemented carbide, which is a composite material made by combining tungsten carbide particles with a metallic binder, such as cobalt or nickel.
High Wear Resistance
One of the most significant advantages of carbide for machining tools is its high wear resistance. Carbide tools can withstand extreme heat, pressure, and friction without losing their shape or edge. This makes them ideal for cutting hard and tough materials, such as steel, titanium, and alloys.
Carbide tools can also maintain their sharpness for a more extended period, reducing the need for frequent sharpening or replacement.
High Hardness
Carbide is one of the hardest materials available, with a hardness level of up to 93 HRA (Rockwell hardness scale A). This makes most solid carbide end mills for sale extremely resistant to deformation and damage, even when subjected to high stress and impact.
Carbide tools can also cut through tough materials without breaking or chipping, which improves the precision and accuracy of the machining process.
High Thermal Conductivity
Carbide has a high thermal conductivity, which means it can dissipate heat quickly and efficiently. This property is essential for machining tools because it prevents the tool from overheating and losing its hardness and strength.
Most solid carbide end mills for sale can maintain their performance even in high-temperature environments, such as those encountered during high-speed machining or drilling.
Corrosion Resistance
Carbide is also highly resistant to corrosion and chemical damage. This makes it ideal for use in harsh environments, such as those found in the oil and gas industry, where exposure to corrosive substances is common.
Most tools such as end mills made of solid carbide can resist the corrosive effects of acids, alkalis, and other chemicals, ensuring their longevity and performance.
Cost-Effective
While carbide tools may have a higher initial cost than other materials, such as high-speed steel or cobalt, they are often more cost-effective in the long run. This is because carbide tools last longer and require less maintenance, reducing the need for frequent replacement or sharpening.
Carbide tools also provide better performance and precision, which can result in higher productivity and profitability for the manufacturing industry.
Carbide is the chosen material for machining tools because of these properties. They make machining tools ideal for cutting hard and tough materials, maintaining precision and accuracy, and withstanding harsh environments.
Choosing carbide as a material for machining tools is a wise decision that can improve the efficiency, durability, and profitability of the manufacturing industry.
Posted May 15, 2023 02:02
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March 23, 2023 03:14
A chamfer end mill is a type of cutting tool used in machining operations, specifically in milling. It is designed with a chamfered cutting edge that allows it to produce angled or beveled edges on a workpiece. Chamfer end mills are commonly used for tasks such as cutting keyways, beveling edges, deburring, and countersinking.
Quality in Selecting Chamfer End Mills
Quality is very important when selecting chamfer end mills. The quality of the tool affects its performance, durability, and precision. High-quality chamfer end mills are made from high-quality materials, such as solid carbide, and are manufactured using strict quality control standards. They are more precise and consistent in their cutting action, resulting in improved surface finishes, more accurate cuts, and longer tool life. Low-quality chamfer end mills, on the other hand, are more likely to break, wear out quickly, produce poor results, and cause tooling problems.
In addition to the quality of the tool itself, the quality of the tool holder and the cutting parameters used can also have a significant impact on the performance of a chamfer end mill. Using the correct tool holder and cutting parameters helps to ensure optimal performance, reduces tool wear, and extends tool life.
Size Does Matter
Size matters when selecting chamfer end mills. The size of the chamfer end mill affects its performance, the size of the cut it can make, and the material it can effectively machine.
The circumference size, or diameter, of the cutting edge, determines the size of the cutting radius and the strength of the tool. A smaller diameter provides a smaller cutting radius and a weaker tool, while a larger diameter provides a larger cutting radius and a stronger tool. The diameter should be selected based on the specific machining requirements, including the size of the feature being cut, the material being machined, and the desired surface finish.
The length of the cutting edge, the overall length of the tool, and the shank diameter are also important factors to consider. These dimensions affect the tool's stability and reach during cutting, and should be selected based on the thickness of the material being machined, the depth of the cut, and the accessibility of the cutting area.
Buy Chamfer End Mill Online
If you're looking for a reliable and efficient way to cut materials to exact measurements, then you need to invest in a high-quality chamfer end mill. These tools are essential for any machine shop, and you can find them for sale online at Online Carbide.
Online Carbide offers a wide selection of chamfer end mills for sale in a variety of sizes. Whether you need a standard end mill or a custom design, you'll find the perfect tool for your project. All of their end mills are made from the highest quality carbide, ensuring that you get a tool that will last for years to come.
Get started today and find the chamfer end mill you need from Online Carbide!
Posted March 23, 2023 03:14
March 21, 2023 01:47
Drill bit manufacturing plays a crucial role in the aerospace industry as it affects the precision and efficiency of drilling operations. The aerospace industry requires high-quality drill bits that can withstand extreme conditions and produce precise holes for various applications such as fastening, assembly, and fuel line installations.
A Complex Series of Steps
Drill bit manufacturers use a process that involves a complex series of steps, including heat treatment, grinding, and coating, that determine the quality and durability of the final product. Improper manufacturing techniques can result in poor performance, reduced accuracy, and increased downtime, all of which can negatively impact the aerospace industry.
Moreover, the aerospace industry is constantly seeking new materials and technologies to improve their aircraft, and the drill bit industry must keep pace with these advancements. The use of new materials such as titanium and composites presents new challenges for drill bit manufacturers.
It requires specialized drill bits and cutting edges that can handle these materials effectively. As the aerospace industry continues to evolve and demand increasingly high-quality and specialized products, the drill bit industry must continue to innovate and adapt to meet these needs.
Drill Bits and the Aerospace Industry
Incorrectly placed drills can increase the risk for the aerospace industry in several ways:
Structural damage
Improperly placed drills can cause structural damage to the aircraft. If a drill bit penetrates a critical component or structure, it can weaken the overall integrity of the aircraft, putting passengers and crew at risk.
Unintended holes
If a drill bit is not properly aligned, it may create unintended holes in the aircraft, potentially leading to leaks or reduced aerodynamic efficiency.
Production delays
If drilling operations are not completed correctly, it can result in production delays, as the damaged parts may need to be replaced or repaired, slowing down the manufacturing process.
Cost overruns
Repairs and replacements due to improperly placed drills can significantly increase the cost of production, leading to cost overruns and reduced profits.
Safety concerns
Improperly placed drills can compromise the safety of the aircraft, creating potential hazards for passengers and crew.
Therefore, it's essential for the aerospace industry to ensure that drill bit placement is precise and accurate, and that drill bits are made from high-quality materials and manufactured to exact specifications. This helps to ensure the safety and reliability of the aircraft, and to prevent production delays and cost overruns.
Precision Drilling Improves Safety
The aerospace industry is heavily dependent on the quality and precision of the drill bits and the parts used in airplane parts. And the manufacturing process plays a critical role in determining the success of drilling operations.
This attention and focus improves the safety of aircrafts, and ensures airline companies that the right tools and materials are used in the manufacture of their planes and equipment. So manufacturers must always check to ensure that the right drills and parts are used for each component.
The aerospace industry will continue to require high-quality and specialized drill bits to meet their demanding requirements, and drill bit manufacturers must continue to innovate and adapt to meet these needs.
Posted March 21, 2023 01:47
March 15, 2023 03:47
Spot drills made of carbide is a cutting tool used in various industries for drilling through hard materials. It is made of carbide, a material that is harder and more abrasive-resistant than usual drill bits. This makes it ideal for use in industries where precision and durability are essential.
What is Spot Drilling?
Spot drills are important in the automotive, aerospace and medical industries because they allow for more accurate drilling. When a spot drill is used, it creates a smaller hole that is more perpendicular to the surface being drilled. This results in a more accurate and cleaner hole. Additionally, spot drills are less likely to wander off course, which can be a problem with regular drills.
Spot drills of carbide are used to create a pilot hole for a larger drill bit, and they are also used to create counterbores and Countersinks. These drills are typically made of high-speed steel or carbide, and they have a variety of features that make them well-suited for different applications.
For example, some spot drills have a split point tip that helps to prevent walking, and others have a flute design that helps to remove chips more efficiently. Spot drills are an essential tool for many industries, and they can be used in a variety of ways to create different types of holes.
The Automotive Industry
In the automotive industry, spot drills in carbide are used to create precise holes for engine components. They are most commonly used in the automotive industry in two main applications: to create pilot holes for dashboard fasteners, and to create starter holes for outer body panel fasteners.
Pilot holes are used in the dashboard assembly process. Dashboards are constructed using a variety of materials, including plastic, aluminum, and steel. To ensure that these materials are correctly fastened together, pilot holes must be drilled into the various layers of the dashboard.
The drill bit size will depend on the fastener being used. Once the pilot holes have been created, the fasteners can be inserted and tightened.Spot drills are also used to create starter holes for outer body panel fasteners. In this application, the spot drill is used to create a small hole in the outer body panel.
The Aerospace Industry
In the aerospace industry, they are used to drill through tough metals used in aircraft construction. Spot drills are used extensively in the aerospace industry for drilling holes in aircraft parts and components. They are also used to create reamer holes and counterbores.
The Medical Industry
In the medical industry, carbide spot drills are used to create implants and other medical devices. Spot drilling is a type of drilling that is often used in the medical industry. Spot drilling is a relatively quick and easy way to drill holes in hard tissue.
This type of drilling is usually done with a drill bit that is slightly smaller in diameter than the final hole that will be drilled. It’s also used in the creation of prosthetics, and other medical equipment.
Spot drilling has many uses in different industries, and without it, most of the machinery and equipment we build relies heavily on the efficiency and accuracy of spot drills.
Posted March 15, 2023 03:47
March 15, 2023 03:17
Flutes are the spiraled grooves in a cutting tool that contact the workpiece and produce and evacuate chips. Basically, they are the part of the mill or drill that enables it to cut.
End mills for sale - as well as other specialty mills and drills - are available in multiple flute counts and variations. Two and four-flute mills are common, but there are higher flute count mills, too.
So, what are the considerations you need to take with flute count?
Flute Count Implication
Flute count has a marked impact on tool performance with respect to cutting ability, tool strength, and chip evacuation.
One important aspect of the cutting tool impacted by flute count is core size, which is the diameter of the cutting tool tangent to the flutes but at the deepest point.
The more flutes a tool has, the greater the core diameter, and therefore, the stronger the tool - all else being equal, of course.
A higher number of flutes also generally results in a cutting tool with a smaller cutting depth, which for the operator means that a higher flute count usually corresponds to a better surface finish on the workpiece.
However, too many flutes can adversely impact chip removal, as larger valleys (the spaces between the flutes) correspond to higher chip evacuation. This makes cutting tools with higher flute counts better for cutting harder materials that require greater core strength, and which will produce more, smaller chips that are easier to evacuate.
Flute Count and Application
Another way to approach the quandary of flute count is by application. For instance, lower flute counts are sometimes used for roughing work where a relatively large volume of material will be removed and speed and chip evacuation are paramount.
The flipside is that tools with higher flute counts are often used for finishing applications, in which a comparatively smaller volume of material will be removed, but in which instance a smoother surface finish is desired.
Machining softer materials like aluminum generally calls for a lower flute count as tool core strength is not in sharp focus, and the lower flute count allows the softer, larger aluminum swarf to be more easily evacuated.
Conversely machining harder materials (like ferrous metals) often calls for cutting tools with a higher flute count, with a higher core strength that is necessary to withstand the abuses of machining.
It is also important to keep balance in mind: a common misconception is “more flutes, more feed.” Since higher flute counts hinder chip evacuation, sometimes a tool with a lower flute count is better for higher feed rates.
Where Can You Find Quality, Solid Carbide End Mills for Sale?
Looking for high performance carbide end mills for sale that are made in the United States? Visit OnlineCarbide.com and check out their collection of end mills, chamfer mills, spot drills, and other cutting tools. They even carry variable pitch end mills which can help reduce machine chatter.
Their prices are great and quality is top-notch - and some orders even quality for free shipping.
Posted March 15, 2023 03:17
March 2, 2023 06:59
As a crucial instrument in the production process, solid carbide thread mills are of great value. They are put to use in the manufacture of finely crafted threads. In addition to steel and stainless steel, they can also cut threads in aluminum and other non-ferrous metals.
In this post, we'll go through the benefits of employing solid carbide thread mills, including increased productivity, accuracy, and tool life, as well as decreased expenses and downtime.
Improved Efficiency
The enhanced efficiency provided by solid carbide thread mills is one of the most significant benefits of employing them. When milling using a solid carbide thread mill, you only need to make one pass through the material to get the desired result; this reduces or eliminates the need for further operations.
These thread mills are substantially more efficient than their high-speed steel (HSS) counterparts in terms of thread production. Manufacturing companies may save a lot of time and money if they can boost output without sacrificing quality by using this type of thread mill.
Precision
For the same reason, solid carbide thread mills have earned a reputation for accuracy. When compared to other thread mills, they are capable of creating more precise threads.
They offer more stiffness and stability than other alternatives since they are produced from a single piece of solid carbide. Its stability and stiffness are crucial for many uses since it guarantees a clean thread-cutting experience.
Longer Tool Life
Moreover, the tool life of solid carbide thread mills is far longer than that of their steel counterparts. As solid carbide is so tough, it may be used in a wide variety of industrial settings.
It may endure considerably longer than other materials since it is resistant to wear and can sustain high temperatures. As they won't need to repair their tools as often, manufacturers may save a lot of money thanks to this improvement in their durability.
Reduced Costs and Downtime
When it comes to cutting expenses and downtime, solid carbide thread mills are a great tool to have on hand. Reduced manufacturing costs are possible with the aid of these mills because of their superior speed and accuracy in creating threads.
Because of their longer lifespan, manufacturers will save money by not having to replace tools as often.
FAQs
Q: What kind of materials may be milled using a solid carbide thread mill?
A: Steel, stainless steel, aluminum, and other non-ferrous metals are all suitable for cutting using solid carbide thread mills.
Q: As compared to high-speed steel thread mills, how do solid carbide ones differ?
A: Solid carbide thread mills, unlike those constructed from other materials, are fashioned from a single block of carbide. As a result, these thread mills are superior to HSS counterparts in terms of accuracy and productivity.
Q: Can threads be made with a single pass using a solid carbide thread mill?
A: Indeed, solid carbide thread mills are built to make threads in a single pass, rather than requiring many passes like conventional mills.
If you're looking for a reliable source to buy a solid carbide thread mill, look no further than OnlineCarbide. Their selection of thread mills is top-notch, and their customer service is unbeatable. Get the quality product you need today from OnlineCarbide!
Posted March 2, 2023 06:59
February 7, 2023 00:30
As metal manufacturing continues to evolve, so too do its trends. The 2023 global market is shifting, and metal fabrication and manufacturing companies can only stay ahead if they expand their capabilities and become more flexible.
Here are the trends that could have a considerable effect in the metal business.
Automation and the Use of Digital Tools
One of the major trends in metal manufacturing is the increasing use of digital tools. This includes 3D printing, CAD/CAM software, and other technologies that allow for rapid prototyping and customization.
Some technologies are allowing manufacturers to check the efficiency of their processes. They can measure and analyze all data that is crucial for fabricators and metal manufacturers, which can streamline their processes and improve efficiency.
As these tools become increasingly accessible, metal manufacturers can create products such as carbide end mill sets faster and with greater precision. This, in turn, increases the efficiency of the entire manufacturing process and allows for more production in less time.
Advanced Materials
Another trend that is becoming increasingly popular is the use of advanced materials. These materials are becoming increasingly important for metal manufacturers as they can create products with higher strength and durability.
This is particularly important for industries that rely on metal components, such as automotive and aerospace. By using advanced materials, metal manufacturers can create components that are more reliable and last longer, such as carbide end mill sets and steel alloy drill sets.
In addition to advanced materials, metal manufacturers are also using more sophisticated processes. These processes, such as laser cutting and welding, allow for greater precision and accuracy. This is beneficial for industries that need highly precise components, such as medical device manufacturers.
Exploration of Sustainable Practices
Metal manufacturers are beginning to use more sustainable practices. This includes using recycled materials, reducing energy consumption, and minimizing waste. These practices help to reduce the environmental impact of metal manufacturing and can help manufacturers save money in the long run.
Reshoring
Reshoring refers to outsourced manufacturing jobs that are now returning to countries or places where they originated. The rising cost of transport and overseas delivery costs have made metal manufacturers focus on local labor, instead of outsourcing it overseas.
Reshoring is now becoming an option for many companies as it is more cost-effective and reliable especially after the pandemic.
What 2023 Promises the Metal Manufacturing and Fabrication Industry
As these trends continue to evolve, it’s important to consider how they will affect other industries in 2023. For example, metal manufacturers will be able to create more efficient and reliable components for the automotive and aerospace industries.
In addition, medical device manufacturers will be able to create more precise components with fewer resources. Finally, sustainable practices will help metal manufacturers reduce their environmental footprint and save money.
Overall, the trends in metal manufacturing will change overtime, and these changes will have a significant impact on other industries in 2023. Metal manufacturers can ensure that their products are reliable, efficient, and sustainable if they keep track of these trends and their developments.
Posted February 7, 2023 00:30
January 23, 2023 02:15
Stub drills are a type of cutting tool used for drilling holes in metal and other materials. They are designed for producing holes of small to medium diameters, usually in the range of 0.5mm to 6mm. These drills are often used in applications such as machine shop operations and general-purpose machining.
Stub drills are characterized by their short length and low cutting forces, making them suitable for use in tight spaces and on thin sheets of material. They are available in a variety of styles, including straight-shank, taper-shank, and threaded-shank designs.
Stub drills are typically made from high-speed steel (HSS) or carbide, with carbide being the preferred material for high-performance applications. Carbide drills are more durable, have higher resistance to wear, and can be used at higher cutting speeds than HSS drills.
When using stub drills, it is important to select the correct size and type of drill for the material being drilled. The type of material and the depth of the hole will determine the optimal size and type of drill to use. Additionally, the type of coating on the drill bit will affect the performance of the drill.
Coatings are used to extend the life of a drill bit and improve its cutting performance. Common coatings used on stub drills include titanium nitride (TiN), titanium aluminum nitride (TiAlN), and titanium carbon nitride (TiCN). TiN coatings are the most common type of coating used on stub drills, as they provide good wear resistance and improved cutting speeds. TiAlN and TiCN coatings are slightly more expensive, but they offer better wear resistance and improved tool life.
When using stub drills, it is important to ensure that the correct cutting speed and feed rate are used. The correct cutting speed is determined by the material being drilled, the diameter of the drill, and the type of coating on the drill. The feed rate is determined by the size of the hole being drilled and the speed of the drill. It is important to use the correct cutting speed and feed rate to ensure the best performance from the drill and to minimize wear on the cutting tool.
Stub drills are versatile cutting tools that can be used for drilling holes of small to medium diameters in a variety of materials. They are typically made from carbide or high-speed steel and are available in a variety of styles. They are also available with a variety of coatings to increase their cutting performance and tool life. When using stub drills, it is important to select the correct size and type of drill for the material being drilled and to use the correct cutting speed and feed rate. By following these steps, you can ensure the best performance from your stub drills and get the most out of your cutting tools.
Quality Stub Drills Online at Great Prices
Machinists looking for new stub drills and other carbide cutting tools should investigate Online Carbide (OnlineCarbide.com). They carry a wide range of solid carbide cutting tools that are made in America; orders $250 even get free shipping.
Check out their website via the link above or get in touch with them at Sales@OnlineCarbide.com.
Posted January 23, 2023 02:15
September 10, 2021 06:31
A lot of people have moved into the machining industry lately. Especially with the appearance of more affordable CNC machines that allow anyone to craft custom parts right from their garage. However, many still render crudely finished products with sharp edges that make them quite dangerous depending on the intended use. That's where chamfer mills come into play.
It is common courtesy to chamfer any sharp edges off your parts or finished products to prevent accidents. Having a piece of furniture or piece that catches on clothes or causes some slashing damage can be grounds for serious problems.
Of course, you can create smooth surfaces by just filing your edges at a 45 degrees angle, or use a grinding disk. But when you´re machining, precision and accuracy are essential.
Chamfer mills provide both precision and speed. They not only take care of rough edges but also leave a much better finish. Additionally, they easily reach difficult angles without a problem and do a great job at smoothing out punched holes and prepping them up for threading.
Now, imagine we not only have to smooth out the surface, but we also need to modify the angle at which two surfaces meet. Carbide chamfer mills help you remove all those nasty 90 degrees edges and corners, creating a better-looking beveled slope while removing burrs along the piece.
This is also useful when preparing a piece for welding as chamfering provides a smooth surface to allow for a much stronger weld, and reduces the need for clearing excess material when finished.
A chamfer mill can also be used for finishing purposes. Carbide cutting tools have very sharp edges that easily remove material, leaving a perfectly polished surface that saves you time by eliminating the need of buffing out imperfections. I have found that machining and chamfering with carbide cutting tools make it easier to get parts that are ready for service right off the bat. Just make sure your bit engages the material correctly when machining tough alloys. A sharp edge can eat through your carbide and chip the tool easily if you´re not careful enough.
You can also use chamfer mills for engraving or creating channels along the surface without having to go through the finishing process. Carbide chamfer mills keep heat under control, allowing the drill to go through a lot of material without the risk of warp or chatter, leaving perfectly polished floors and walls.
So, even when your CNC or machining operations require minimum finishing, smoothing out edges and offering a polished surface is always a plus when delivering metal parts. We recommend having a few carbide chamfer mill bits in your arsenal. However, make sure they´re made here in the US from a manufacturer with great reviews. Our favorite is www-onlinecarbide.com as they offer incredible wear resistance and a great variety of tools for machining both soft and hard alloys. Their sales representatives are top of the line and provide advice on the right bits or angles for your machining projects.
Posted September 10, 2021 06:31
September 6, 2021 09:08
Threads are an essential part of all sorts of components and connectors. From the pipes that feed water into our homes to the machines that make building those homes possible, threaded surfaces literally hold everything together. The process of cutting threads has taken many different forms over the years. Thanks to the popularity of CNC milling machines in the area of manufacturing, thread milling has become a popular way to add threaded surfaces to pipes and custom made components. If you want to thread mill efficiently it is important to know when to use single pitch thread mills.
Traditional thread making tools like taps and dies can have their drawbacks. They can take time and often require tool changes to produce threaded surfaces of different diameters and pitches. When chips fail to evacuate from these tools they can also cause some serious jams, potentially damaging the workpiece or the tool itself. Thread milling tools can tackle the same tasks in seconds with significantly less risk of the tool jamming or causing issues during the cut.
Some of the most common thread milling tools are known as full form tools. While these cutters are extremely fast and efficient, they are not always the best fit for a job. These thread cutting end mills have rows of sharp cutting teeth that are spaced to correspond to the desired thread pitch. When making a cut, the tool moves in a 360 degree angle while dropping the length of a thread pitch in order to form a uniform helical thread.
While this process allows threads to be cut in a second or less, it's still not always the best choice. Every full form tool can only cut threads with a uniform pitch, though they can be used to cut internal or external threads that are either left or right handed. These tools should only be used on very stable workpieces because they have a large cutting surface. If you have to deal with mixed thread sizes or unstable worpieces, then single pitch thread mills might be the best tools for the job.
Single pitch thread mills are designed with only a single cutting point instead of the full row of points found on a full form thread mill. This means that the tool has to trace along the entire threaded surface, which will take longer than using a full form tool. While the process might take a little longer, a single tool can create threads with a wide range of different pitch sizes, making them a great option. They can also be used to thread delicate surfaces like thin walled components and overhangs with ease.
If you are looking for some single pitch thread mills for your shop, then Online Carbide is the brand to check out. Their US made thread mills are second to none and are ground from high quality tool carbide stock. You can see their thread mills and all of their other cutting tools when you visit www.onlinecarbide.com.
Posted September 6, 2021 09:08
September 3, 2021 06:02
When it comes to accuracy, milling machines are truly amazing tools. They are capable of performing extremely complex operations very quickly to shockingly tight margins of error. Sadly certain longer cutting tools like drill bits are not always the most accurate when using these machines. Luckily using spot drills to your machining process can significantly improve how accurate your longer twist bits can be.
So what is the issue with drill bits? Simply put, the issue is tool vibration. All high speed tools oscillate slightly due to the centrifugal forces they are encountering. When the tool is long relative to their width like a drill bit, this effect can be a little more pronounced. This can lead to the tool having enough of an oscillation that the point of the bit will be swinging around the center of the bit's rotation.
When a bit that is oscillating contacts a hard surface, it can deflect instead of penetrating as intended. This can even cause the drill bit to walk off its mark entirely. Obviously this is a big issue, especially when accuracy is crucial on your workpiece. One of the best ways to improve your accuracy is to create a surface that will provide your drill bit with an easier location to drill. This can be achieved through spotting.
Spotting is the process of creating small dimples on the surface of a workpiece to mark the location of future holes. The process is almost like countersinking for a hole that does not exist yet. The best tool for spotting is a spot drill. Unlike your average drill bit, a spot drill is not designed to drill deep holes. Instead, they are limited to a fluted point that is made to cut cone shaped dimples into your workpiece. These tools are short by design, which makes them extremely stable. Carbide drills are a great option because carbide's structure is more rigid and tolerant of heat than other tool materials like high speed steel.
The process of spotting is usually quick and easy, all you need to do is make sure the spot drill has a point angle that is larger than or equal to the point angle of your longer twist drill bit. As long as this is the case, you can drill all of your spots so that your longer twist bits will hit their marks perfectly. It's also important to make sure that you are using a proper spotting drill and not a center drill or similar looking tool that often may have a smaller point angle.
If you need high quality spot drills for your shop, then you can find some high performance solid carbide options when you visit www.onlinecarbide.com. All of Online Carbide's tools are manufactured in America using high quality carbide stock. If you have any questions about any of the tools that they offer, feel free to reach out to a member of their team by sending an email to sales@onlinecarbide.com.
Posted September 3, 2021 06:02
August 30, 2021 05:58
If you are not already using TiAlN coated end mills, you might want to make the switch. End mills and other milling cutters have to tolerate extreme forces and temperatures, which can shorten their tool life. If you are not using coated tools, then you might not be getting the most out of your cutters.
End Mill Fatigue
All high speed tools have to deal with fatigue. The strain caused by friction at high speeds is immense and can even damage your tools. This is particularly true with end mills made from steel alloys due to the fact that their hardness is directly related to the temperature at which they are tempered. If the heat from friction rises above the tempering point, the structure of the metal can realign into a pattern that is not as hard, limiting the effectiveness of its edges.
One way to avoid this is to use tools made from carbide, which get their cutting power from grains of carbide ceramic embedded in the tool stock instead of from heat tempering. Despite being more resistant to heat and lasting longer than steel tools, carbide tools will still fatigue over time. One of the best ways to extend the life of any milling cutter is to coat it in a material like TiAlN.
Titanium Aluminum Nitride
Known by its chemical shorthand TiAlN, titanium aluminum nitride is a special metastable tool coating. TiAlN coated end mills are capable of deflecting heat away from the body of the cutter and into the chips. One of the biggest benefits of TiAlN is the fact that it has a low coefficient of friction, which helps to limit wear resistance and less heat is generated. When heated, TiAlN produces a layer of aluminum oxide that helps to provide extra insulation during high heat applications.
Physical Vapor Deposition
Now when you think of a tool coating, you might worry that the thickness of the coating material could interfere with the sharpness of the tool's edge. This would certainly be the case if we were talking about a coating that was crudely applied like paint, but tool coatings are deposited using physical vapor deposition. There are several techniques that are used but all involve placing the tools into a vacuum, vaporizing the coating material, and then having it resolidify on the tool surface. The major advantage of this is that a stable coating that is a fraction of a millimeter is achieved. Because the process takes place in a vacuum, the coating bonds directly to the body of the tool and offers incredible protection.
If you are interested in having tools that can run faster and last longer, then the TiAlN coated end mills available from Online Carbide are the perfect option. These tools are precision ground in the Us from high quality carbide and treated with titanium aluminum nitride TiAlN coating to offer a smooth surface finish that can withstand high temperatures. All of their tools are available at manufacturer direct prices when you visit their online store at www.onlinecarbide.com.
Posted August 30, 2021 05:58
August 27, 2021 02:20
Milling machines are amazing pieces of machinery for several reasons. Using specialized cutting tools, a computer guided milling machine can perform extremely complex jobs in a fraction of the time that it would take using other machines. One of the downsides to operating at high speeds is the fact that it can often lead to extremely loud tool chatter. The best way to cut down on chatter without slowing down production is to switch to variable end mills.
Tool chatter is a noise caused by the vibrations of your cutting tools. The effects of chatter can vary dramatically depending on the materials being cut, the end mill being used, and the speed and feed rates being used. All tools vibrate at high speeds because even very solid feeling materials like metals are actually flexible. To imagine the issue at hand, picture what would happen if you spin a length of rope between your hands. The rope with flex and bow outward and the exact same thing happens with your cutting tools, albeit to a lesser degree.
The tool paths being used by your machine cannot perfectly account for this effect. This means that your tools are swinging into and impacting the workpiece constantly, occasionally putting a large amount of strain on both the tool and the edge of the workpiece. Because these tiny impacts are occurring a fraction of a second apart, the sound that they make combines into a high pitch screeching sound.
Operating at lower speeds can help to reduce tool chatter, but it will also cost you time. If you want to maintain a fast paced production without having to deal with the ear splitting noise, then using a variable end mill might be the perfect solution. The idea of these tools is that they are designed to be slightly asymmetrical. This leads to the impact forces between cuts being slightly different.
So what is the advantage of asymmetry in your end mills? It's easiest to explain by imagining the process of dribbling a basketball. When you dribble a ball, you apply the same force every time the ball reaches your hand, which leads to a stable rhythm. That is the same thing that happens to your tools. When the impact force is uniform and the timing is evening spaced, the tool builds an internal oscillation that amplifies the vibrations. Variable end mills apply uneven forces, which makes it harder for the tool to reach a consistent rhythm. By breaking up those regular internal forces, you can reduce chatter and harmonics.
If you are tired of dealing with tool chatter, then adding some variable end mills to your arsenal is the perfect way to keep the volume down without slowing down production. You can find high performance variable helix end mills when you visit www.onlinecarbide.com. All of Online Carbide's tools are manufactured in the US from high quality solid carbide stock and are available at manufacturer direct prices. Pay them a visit if you are looking to save big on the tools that your shop needs.
Posted August 27, 2021 02:20
August 13, 2021 03:22
Spot drills and center drills are part of any drilling and machining operation. One of the most important aspects of machining parts is to drive holes with laser precision accuracy. You know that a hole that is off by a tenth of a millimeter can render a part useless, and there are no “undo” hotkeys in this business.
The problem is that twist drills or “jobbers” tend to “walk-off” when they first come in contact with a surface, especially when milling hard metal and alloys, no matter how tightly secured they are to the spindle. This happens because they are usually longer and more flexible than stub and spot drills.
Center Drills
Now, many CNC enthusiasts like using center drills for spotting since they are usually cheaper, and easier to find. However, the intended function of a center drill is to create a hole that helps secure a part in a lathe.
I can see why it might be the first pick for many when they understand the importance of spotting, as the pilot tip might suggest that it is its main purpose. However, if your operation requires a lot of spotting, the brittle center drill tip will not last too long.
There is one other problem: the countersink. When you're spotting, you want a hole angle that is equal to or greater than the twist drill angle. If the opening is too narrow, the recently drilled dimple will be a death trap for your bits, especially if they´re carbide-coated.
Now, it does not mean that center drills are not good for spotting. They do a good job as long as you only use the tip of the pilot, and don't abuse the tool. As we said before, the tip is very brittle and can only take you so far.
Spot Drills
True spot drills are the perfect tool for the job. They are chubby and rigid and generally provide the perfect anchorage for your jobber. The chunky shank helps to keep the tip right on target, providing maximum accuracy, and preventing it from walking off.
Some might say that spot drills are not necessary, or even detrimental if you´re using carbide drills. However, longer drill bits with carbide-coated tips are still too flexible and will deflect off or even start a hole at the wrong angle.
So, what's the solution?
Just remember that the tip angle of your twist drill must at least match that of your spot drill. That is the best way to protect your sharp carbide edges to come in contact with tapered angles that can damage your carbide tips. A matching point angle will help your tool find purchase quickly and engage the material right off the bat.
There seem to be very few trustworthy spotting drill bit suppliers. If you want excellent customer service and really durable tools, visit www.onlinecarbide.com. They manufacture all of their carbide bits and have plenty of spot drills to choose from.
Posted August 13, 2021 03:22
April 10, 2021 07:08
When it comes to milling tools, chamfer mills are incredibly useful little cutters that often get overlooked. While they are not the tool that you reach for when starting a new project, they are still an important tool in the milling industry. Today we'll be taking a look at the American made Chamfer cutters available from Online Carbide and how they can be utilized in your shop.
Online Carbide is an American tool manufacturer specializing in carbide milling cutters. Their inventory includes a wide range of high performance end mills and drill bits made from solid carbide. Due to its ceramic and metal composite nature, tool carbide is incredibly rigid and holds its edges well, especially under high speed and high heat conditions.
On the Online Carbide website, you will find a handful of high quality chamfer end mills. Chamfer mills are relatively simple tools with a straight shank terminating in a small pointed cutting surface. These points contain four cutting flutes and they are designed to perform a wide range of important tasks at the end of the machining process.
When you have completed the bulk of your material removal, most of the edges on your workpiece will probably be hard 90 degree angles. Chamfering is the process of softening these hard edges by creating an intermediate plane where the two sides of the corner meet. This helps to make the final workpiece easier to handle and help to remove any burrs along the edges of your piece. This process is often confused with beveling, which involves removing material to change the angle at which two sides meet. A chamfer cutter can be used to complete both of these tasks with ease.
In addition to chamfering and beveling, these tools can be used for a wide range of other finishing tasks. Their short length and sharp points make them ideal for handling precision milling operations. As we mentioned earlier, the process of chamfering can help to remove burrs from a workpiece. In addition to this, the point of a chamfer mill can trace along the finished edges of a piece to remove burrs without adding a chamfer to the edges of your workpiece. You can also use the point on a chamfer cutter to perform a wide range of other finely detailed tasks such as engraving details of your workpiece.
You can order quality American made chamfer mills by visiting www.onlinecarbide.com. Like all of their tools, these cutters are made from solid micrograin tungsten carbide tool stock precision ground using 5 axis grinders. They have ¼", ⅜", and ½" chamfer cutters with both 60 degree and 90 degree point angles. As an added bonus, all of their tools are available at manufacturer direct prices so you can save big on the tools you need for your shop. If you have any questions about any of their tools, feel free to reach out to a member of the Online Carbide team by sending an email to sales@onlinecarbide.com.
Posted April 10, 2021 07:08
December 1, 2020 01:50
When it comes to manufacturing custom components with a milling machine, using the right cutting tools for the job is essential. Most end mills are specifically designed to perform a certain task. This means that completing a custom component that requires making several different types of cuts using a variety of tools. If you are looking to cut down on product times, tool changes are a good place to start. Tools like chamfer mills can be surprisingly versatile for those who know how to use them.
The most obvious use for these tools is chamfering, hence the title. The process of chamfering involves removing material from a corner where two planes meet to create a third plane that breaks the edge. This process is often confused with beveling, a similar technique that involves removing material to chamfer the angle of a corner completely. A chamfer cutter can perform both of these tasks. The size of the bevel or chamfer may require multiple passes depending on the size of your tool’s angled cutting edge.
Chamfer mills can also be used to to deburr a workpiece. CNC machining is fast and accurate, but sadly it is not always perfect. Same raised metal burrs are a common side effect of high speed machining and these small bits of metal can create sharp surfaces that can interfere with how components fit together and cut anyone who handles the finished product. By tracing along the edges of a workpiece with a chamfer tool, you can quickly and easily remove any small burrs much faster than attempting to spot and remove them manually.
These tools can also be used to spot drill locations for holes. Drilling accurate holes with a milling machine is often a multiple step process and spotting is the process of creating a small dimple in the workpiece with a short and stable tool. This dimple makes it easier to mark locations for drilling deeper holes that will help avoid longer drill bits “walking” off their mark and potentially ruining your workpiece. During the finishing process, chamfer tools can also be used to countersink holes so bolts can sit flush with the surface after installation.
In addition to performing these tasks, you can use your chamfer cutter to perform fine detail work. The sharp point and short length of these little milling cutters makes them a great choice for engraving and adding other small details.
If you are looking for high quality chamfer mills for your shop, you can find some great options at Online Carbide. As an American manufacturer of solid carbide end mills and drill bits, they consistently manufacture reliable and accurate tools that are available at manufacturer direct prices. You can see their full catalog when you visit www.onlinecarbide.com. If you have any questions about their chamfer cutters or any of their other tools, feel free to reach out to a member of the Online Carbide team by sending and email to sales@onlinecarbide.com.
Posted December 1, 2020 01:50
November 24, 2020 01:24
A chamfer end mill is not exactly the most impressive looking cutting tool, but looks can be deceiving. Chamfer cutters are one of the most versatile milling cutters found in most shops. These tools are typically just a shank with a pointed and fluted tip, though there are some more elaborately designed chamfer tools on the market. Some tools may have flutes moving beyond the tip of the tool, special cutting edges to work with a variety of materials, or other design features based on the company producing the tool. Whether you are new to milling or you are looking to find the best chamfer tools, understanding what these tools are designed for is essential.
Obviously these tools are designed to produce a chamfered edge. Chamfering involves removing a portion of a corner on a workpiece in order to create a new plane to replace that corner. This helps to soften sharp edges or removes material to create a smoother transition between edges while reducing the weight of a finished piece.
The process of chamfering is often confused with beveling. While chamfering adds a third plane to transition between two other planes, beveling is the process of removing material to change the angles at which two planes meet. Any edges that have been machined to no longer be square is considered beveled. These two terms can be used interchangeably, typically in favor of describing both beveled and chamfered edges as “beveled”. A chamfer tool can be used to chamfer or bevel an edge, though the process of beveling may require several passes depending on the size of the tool’s cutting surface.
These two functions are the basics of using a chamfer end mill, but they only scratch the surface of these tools’ versatility. Chamfering is typically performed towards the end of the machining process in order to clean up the freshly machined edges. To this end, a chamfer mill can also be used to deburr a workpiece by tracing all of the cutting edges in order to cut and remove any small burrs that were turned up by the machining process.
You can also use your chamfer mills to spot drill locations for holes if you do not have a spot drilling tool handy. The short length and small cutting surface on these tools make them rigid and accurate, two traits that are perfect for spotting applications. The accuracy of these tools also makes them a great option for engraving and other detail work that requires a small fine point.
If you are looking for high quality chamfer end mills for your shop, Online Carbide has the tools for you. As an American manufacturer of end mills and drill bits, the team at Online Carbide are dedicated to producing high performance tools made from solid carbide. If you have any questions about their tools, feel free to reach out to a member of the Online Carbide team by sending an email to sales@onlinecarbide.com.
Posted November 24, 2020 01:24
November 9, 2020 04:29
Milling machines are powerful manufacturing tools, especially when it comes to machining custom components. One of the few downsides to these machines is the fact that they require specialized cutters in order to operate efficiently. The more tool changes that an operator has to make, the more drawn out the machining process can be. This means that it is important to use certain tools like chamfer end mills as efficiently as possible in order to limit your tool changes and increase the efficiency of your shop's manufacturing process.
What is a Chamfer Tool
Chamfer mills are relatively simple cutting tools. They typically feature a straight shank with a pointed tip that will typically have a few cutting edge flutes. The tips on these unique end mills usually range from 60 degrees to 90 degrees, with the angle affecting the type of angled cuts that the tool can perform. In order to ensure the most accurate results, the best chamfer tools will be constructed from rigid carbide tool stock.
Chamfering and Beveling
As their name would imply, your chamfer end mills are mostly going to be used to chamfer edges. The process of chamfering helps to “break” an edge. Sharp square edges can be unpleasant to handle, so a chamfer tool creates a sloped plane between two sides of a workpiece’s edge in order to soften the edge and create a clean transition.
The process of chamfering and beveling are often confused. While a chamfer aims to soften an edge by creating a new plane, a bevel changes the angle of one of those sides. If a chamfer is expanded until it reaches the terminal point of an edge, it would become a bevel. As long as your chamfer tool’s angle matches the desired angle of a bevel, you can typically complete the process in a few passes.
Finishing and Deburring
In addition to altering the transitions between edges, chamfer end mills can also be used to help finish your workpiece. While high speed milling is fast and accurate, the process is not always perfect. Usually there will be some burrs along the edges of your workpiece. These small burrs can be easy to miss, especially when trying to remove them manually. Because burrs can easily cut or jab anyone who handles the finished piece or interfere with the installation of parts, their removal is essential. The pointed tip of a chamfer mill can be used to trace along all of your pieces’ edges in order to remove these burrs quickly and efficiently.
If you are looking for some reliable chamfer end mills for your shop, you need to check out the options available at Online Carbide. As an American manufacturer of high quality solid carbide end mills, the team at Online Carbide are dedicated to making great tools that are available at manufacturer direct prices. To see their entire inventory of end mills and drill bits, visit their online store at www.onlinecarbide.com.
Posted November 9, 2020 04:29
December 5, 2019 05:54
When it comes to machining components that need to have solid connections, you need to make sure that you have accurate thread mills. The process of thread milling requires making highly accurate cuts so that your components will be able to fit together as intended. If you want to ensure accurate results, you need to complete your work using Solid Carbide Thread Mills. Here at Online Carbide, we make all of our milling cutters to our exact standards using top of the line solid carbide stock. These tools are designed to perform the cuts you need within precise tolerances and can cut a diverse number of thread designs to meet any shop’s needs.
Thread milling is a tricky but necessary part of machining. This process used to only be completed using specialized tools call taps and dies. These tools can cut accurate threads, but often require the operator to cut the threads by hand, which can be cumbersome and time-consuming. Using thread mills is a great way to simplify this process.
Here at Online Carbide, we offer two styles of thread mills. The first style is our single pitch thread mills. These end mills are designed with a small shank and a round cutting head with a rough rhombus-shaped cross-section. These tools are suited to a wide range of thread cutting needs including medium to large internal threads of larger external threads, particularly on asymmetric components. They are also ideal for components that are not extremely stable, due to their small cutting surface. This makes them perfect for thin-walled parts or dealing with large overhangs. You can also use these single pitch mills to cut the same insert sizes, but with different thread pitches.
Our next option is our full form thread mills. These mills have a sturdy tapered cutting surface with threads and rows of triangular “teeth” between the threads. Unlike single pitch mills, these end mills are designed to complete your part’s threads using one 360-degree cut. As long as the thread pitch is identical, these end mills can cut multiple thread sizes with the same tool. They will also chamfer while they cut your threads.
We offer all of our solid carbide thread mills in a range of sizes. Our Single pitch thread mills are sold based on thread size and threads per inch. Our full form thread mills are divided based on UN, metric, NPT, and NPTF thread options. All of our thread mills are coated with a TiAlN layer to protect from heat and extend their tool life.
So if you work in a shop that regularly has to cut threads, it’s time to look into the high-quality solid carbide thread mills from Online Carbide. All of our cutting tools are made using the highest quality carbide stock and ground to exact tolerances using our robot FEC 5 Axis CNC grinders. If you have any questions about our inventory, feel free to reach out to a member of our team via phone at 630-238-1424 or email at sales@OnlineCarbide.com.
Posted December 5, 2019 05:54
November 28, 2019 22:34
While machining harder materials like steel can but some serious wear on your end mills, people often underestimate how difficult machining soft aluminum can be. If you go into an aluminum milling project without the correct cutting tools, you may damage both your cutter and your workpiece. We have looked at the challenges aluminum can pose and have created the Best End Mills For Aluminum in order to help our customers machine with ease.
Here at Online Carbide, we are dedicated to providing our customers with top of the line carbide cutting tools. We use the same high-quality solid carbide stock as other industry leaders, we never offer carbide coated or tipped tools. We use robot fed 5 axis CNC grinders to produce our cutting tools to precise tolerances. This helps ensure that every tool we sell will perform as expected. We also only sell directly to our customers. These manufacturer direct prices will help you avoid the mark up that most stores put on cutting tools after purchasing them from the manufacturer.
There are several aspects of aluminum that can make it a tricky material to machine. The biggest concern when working with aluminum stems from the small chips that are produced. The chips from aluminum are so small they are basically a powder. This means that if the chips are difficult to evacuate from the cutting area. If too much aluminum powder builds up about your cutter, it can easily start to cake up back into a solid mass. If this occurs it can severely damage your end mill.
In order to help with chip evacuation, the best end mills for aluminum will have a lower flute count compared to tools for steel. This gives the chips more room to evacuate. We make our end mills using a 37-degree helix angle which is also intended to increase the evacuation rate. These features make it much easier to work on aluminum without worrying about unexpected tool failure.
The final feature that makes our end mills the best end mills for aluminum is the coating. We coat all of our tools intended for aluminum with a layer of zirconium nitride. This is a golden-colored ceramic coating that has extremely low surface friction, making it harder for chips to stick. It also helps to greatly increase the life of tools by protecting the tool’s cutting surfaces.
If you work in a shop that regularly deals with machining aluminum, you know how important it is to attack every job with the right tools. If you’re ready to upgrade to the best end mills for aluminum, it's time to visit us at Online Carbide. If you have any questions about our end mills for aluminum or any of our other products, feel free to contact a member of our team at sales@onlinecabide.com or call us weekdays between 8-5 CST at 630-238-1424.
Posted November 28, 2019 22:34